What I am using is Vinyl PVC - no the CarveWright does not melt it - carves like butter (no grain to deal with). I have turned the guys at CarveWright onto it and some of the STL guys (for Models). Yes it is the same stuff that they use as exterior trim.

It finishes (sand, carve, paint, etc...) as good if not better than wood. The beautiful thing about this stuff is that it lasts forever outside. No Rot and no sun issues, hence the combo of the Vinyl and the PVC.

My advice. Find a jobsite in your area and see if they have any cut-offs.

The stuff that I am using can actually be puchased in upto 4x10 feet sheets..... they use it as trim on alot of new houses. Go to the millworks department at your local home store and look for vinyl PVC - they should have have it in 8inch widths.

Interesting because I am cutting Large letters out of a PVC product that goes by the name kometek or Intecel . IT is basically the same as the product you are using Jason as the Same company makes the PVC boards that go on homes. I have not tried Carving with it yet but Considering what you have said here I will not fear breaking the carving bit as much as I did before. Any suggestions on Painting ?